w w w . a u t o s t e e l . o r g

w w w . a u t o s t e e l . o r g

Great Designs in Steel is Sponsored by:AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA,

Nucor Corporation, Severstal North America and United States Steel Corporation

w w w . a u t o s t e e l . o r g

Tailor Welded Coils:Tailor Welded Coils:Applications, Results & Body Structure ImpactApplications, Results & Body Structure Impact

Mark EisenmengerTWB Company LLC

w w w . a u t o s t e e l . o r g

Agenda

Review Tailor Welded Blank Applications

Evolution of Tailor Welded Blanks to Tailor Welded Coils

Application and Results of Tailor Welded Coils

BIW Impact with Tailor Welded Coils

w w w . a u t o s t e e l . o r g

Tailored Product Benefits

GeneralProduct Benefits

Part Reduction/IntegrationMass/Weight SavingsImprove Functionality

Manufacturing BenefitsReduce Manufacturing Complexity Improve Dimensional Control

Cost BenefitLower Tooling & LaborReduce Number of OperationsLess Material Handling & Enhanced Logistics

Material Cost Reduction (MCR)Improved Material Utilization

NestingScrap Reduction

• Optimize Steel Properties Throughout the Part

w w w . a u t o s t e e l . o r g

Tailor Welded Blank Applications

There are 18 common tailor welded blank automotive applications

w w w . a u t o s t e e l . o r g

Welding Process

Butt Weld (no filler)Continuous Flow Welding processGauge Possibilities: 0.4mm to 3.5mmWeld Lengths – up to 4 metersMaterial Combinations Include:

Stainless CR, HR, Zn Coated, DP, TRIP,CP and boron gradesEach weld is computer monitored and serialized

w w w . a u t o s t e e l . o r g

Quality Monitoring

TWB utilizes:Online

Weld profile monitoringMagnetic Flux Leakage Detection (MFL)

SamplingCross sectional analysisVisual inspection

Result: Six Sigma Quality Levels (External PPM 3 or less!)

w w w . a u t o s t e e l . o r g

Tailor welded coils provide specific product benefits:

Exact grade, coating and gage of steel where it is needed.

Cost reduction with part consolidation.

Lighter weight and improved part performance.

Tailored products in coil fed products such as progressive die and roll-forming.

A Breakthrough ProcessTailor Welded Coils:

w w w . a u t o s t e e l . o r g

Continuous process that consists of:

Un-coiling / LevelingWelding Re-coiling

Process OverviewTailor Welded Coils:

Monitoring &Reporting

w w w . a u t o s t e e l . o r g

Utilize the same quality criteria for tailor welded blanks and tailor welded coilsWeld defects are identified and mapped for each coilThe result is improved material utilization with minimal material loss

Coil Map

Quality MonitoringTailor Welded Coils:

w w w . a u t o s t e e l . o r g

Weld defects are identified and mapped for each coil with customer specified methods

Typical methods include: Punched hole, Ink jet, Metered report

Punch

Punched Hole

Weld Defect

Ink Jet

Coil Map ExampleTailor Welded Coils:

w w w . a u t o s t e e l . o r g

Production MachineTailor Welded Coils:

w w w . a u t o s t e e l . o r g

Progressive Die TWC Applications

There are more than 35 potential tailor welded coil automotive applications

w w w . a u t o s t e e l . o r g

Potential Applications for TWC

Seat tracks, supports and seat frames Door intrusion beamsDoor belt reinforcementRoof headers and railsRoof cross railsPlenum floorBumper beamsSillsFloor pan strainerChassis componentsRail back platesSun roof reinforcements

Door beam

w w w . a u t o s t e e l . o r g

Progressive Die Operation

Coil fed operations with tailored steel enable:

lower die & assembly investmentmaterial savingspart weight savingsimproved part performanceimproved dimensional control

Finished PartTailored Coil

w w w . a u t o s t e e l . o r g

Progressive Stamping TWC Parts

Saves 2.0 pounds / vehicleSaves $1.50 / vehicle2 parts / vehicleIn production (Germany)

Longitudinal Chassis Beam

w w w . a u t o s t e e l . o r g

1.35 mm

Roof Cross Member

Progressive Stamping TWC Parts

1.0 mm1.35 mm

Integrates 3 stampings into 1

Improved roof crush and side impact resultsSaves .8 lbs / vehicleSaves $1.60 / vehicleIn production (Germany)

w w w . a u t o s t e e l . o r g

Part developed by .dwg Design Services

Roof Bow

Progressive Stamping TWC Parts

1.8 mm1.0 mm

Integrates 3 stampings into 1

Improved roof crush and side impact resultsSaves 2.0 lbs / vehicleSaves $2.25 / vehicleProposed (USA)

1.8 mm

w w w . a u t o s t e e l . o r g

Improves part stiffnessConsolidates 2 stampings into 1Eliminates assemblyStainless steel 439 Saves .25 lbs / partSaves $.95 / vehicleProposed (USA)

Part developed by .dwg Design Services

Heat Shield Assembly

Progressive Stamping TWC Parts

2.3 mm 0.7 mm

0.7 mm

w w w . a u t o s t e e l . o r g

Saves 2.0 lbs / vehicle (4 parts / vehicle)Costs $.60 / vehicleProposed (USA)

Part developed by .dwg Design Services

Seat Side Member

Progressive Stamping TWC Parts

2.1 mm

1.0 mm

w w w . a u t o s t e e l . o r g

Integrates 2 stampings into 1Improves interface stiffness Saves .3 lbs / applianceSaves $.45 / applianceProposed (USA)

Part developed by .dwg Design Services

Appliance Mounting Bracket

Progressive Stamping TWC Parts

1.7 mm

1.0 mm

1.3 mm

w w w . a u t o s t e e l . o r g

Austenitic Stainless SteelSaves 1.0 lb / vehicleSaves $1.42 / vehicleIn production (Germany)

Muffler Shell

Progressive Stamping TWC Parts

1.2 mm

1.2 mm

0.7 mm

w w w . a u t o s t e e l . o r g

Transfer Press Stamping TWC Parts

2000 Ton Transfer Press580 MPa 1.2 mm / 780 MPa 1.1 mm

Reinf. Compt RR S/Rail

Coil Feed Finished Part

Draw TrimPierce

FlangeRe-strikeCut Cam

Pierce

w w w . a u t o s t e e l . o r g

BaselineBaselineBaseline

Part Consolidation Savings Example

(2) parts are designed and stamped as

progressive die and assembled

Parts are consolidated as a tailor welded

blank and stamped in a transfer press

Parts are consolidated as a tailor welded coil

and stamped in a progressive die

Investment: $575KPiece Cost: $7.20Weight: 3.62kg

Investment: $395KPiece Cost: $6.69Weight: 3.40kg

Improves:Investment: 31%Piece Cost: 7%Weight: 6%

Investment: $345KPiece Cost: $4.97Weight: 3.40kg

Improves:Investment: 40%Piece Cost: 31%Weight: 6%

w w w . a u t o s t e e l . o r g

Progressive Die Potential TWC Impact

Optimizing 33 parts tailor welded coil applications

Upper Body

Front End

Under Body

w w w . a u t o s t e e l . o r g

Potential Impact to BIW Structure

Upper Body (10 applications)6.5 kg of weight savingsProvides the best cost / weight savings ratio

Front End (6 applications) 4.4 kg of weight savingsProvides the highest percentage of weight savings

Under Body (17 applications)12.8 kg of weight savingsProvides the highest number of applications

25 kg of potential weight savings with TWC in BIW

w w w . a u t o s t e e l . o r g

Key Advantages for TWC

Many parts have a calculated 25% stamping cost

savings with the benefit of weight savings

Lower die investment costs

Potential to convert to more efficient press lines:

tandem press to transfer press

transfer press to progressive press lines

w w w . a u t o s t e e l . o r g

A Cost Effective Materials Approach

Tailored Coils bring tailor welded blank benefits to progressive die, coil fed stamping processes and roll-forming applications

Tailored products achieve cost effective weight savings to your programs

Summary:

w w w . a u t o s t e e l . o r g

Thank you!

w w w . a u t o s t e e l . o r g

w w w . a u t o s t e e l . o r g

Great Designs in Steel is Sponsored by:AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA,

Nucor Corporation, Severstal North America and United States Steel Corporation